U.S. patent application number 11/552950 was filed with the patent office on 2007-03-08 for beverage container with integral flow control member having vent and outlet pinhole membranes and safety button.
This patent application is currently assigned to Insta-mix, Inc., Subsidiary A (dba UMIX, Inc.). Invention is credited to James W. JR. Holley.
Application Number | 20070051727 11/552950 |
Document ID | / |
Family ID | 37432132 |
Filed Date | 2007-03-08 |
United States Patent
Application |
20070051727 |
Kind Code |
A1 |
Holley; James W. JR. |
March 8, 2007 |
Beverage Container With Integral Flow Control Member Having Vent
And Outlet Pinhole Membranes And Safety Button
Abstract
A non-spill beverage container includes a cap having a tube-like
spout and a baffle mounted inside the spout, and a flow control
member having a spout (first) membrane supported over the spout
opening. A vent (second) membrane that is disposed adjacent to the
spout and is supported over a vent opening defined in the cap. The
spout and vent membranes are punctured to form multiple,
substantially round pinholes that remain closed to prevent fluid
flow under normal atmospheric conditions, and open to facilitate
fluid flow under an applied pressure differential (e.g., when
sucked on by a child). The baffle limits the differential pressure
applied to the spout membrane when the container is not in use. The
flow control member can only be removed from the cap by removing
the cap from the container body and pressing a flexible safety
button from an inside surface of the cap.
Inventors: |
Holley; James W. JR.;
(Colorado Springs, CO) |
Correspondence
Address: |
BEVER HOFFMAN & HARMS, LLP;TRI-VALLEY OFFICE
1432 CONCANNON BLVD., BLDG. G
LIVERMORE
CA
94550
US
|
Assignee: |
Insta-mix, Inc., Subsidiary A (dba
UMIX, Inc.)
Colorado Springs
CO
|
Family ID: |
37432132 |
Appl. No.: |
11/552950 |
Filed: |
October 25, 2006 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
11131721 |
May 17, 2005 |
|
|
|
11552950 |
Oct 25, 2006 |
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Current U.S.
Class: |
220/367.1 ;
220/203.11; 220/714; 220/717 |
Current CPC
Class: |
A47G 19/2272
20130101 |
Class at
Publication: |
220/367.1 ;
220/714; 220/717; 220/203.11 |
International
Class: |
B65D 51/16 20060101
B65D051/16; A47G 19/22 20060101 A47G019/22 |
Claims
1. A beverage container comprising: a container body defining a
beverage storage chamber and an upper opening; a cap mounted on the
container body such that an upper wall of the cap covers the upper
opening, wherein the cap includes a spout structure including: a
tube-like spout wall having a first end and a second end, the spout
wall defining a fluid flow channel extending from the first end to
the second end of the spout, the flow channel having a first width;
and a baffle disposed in the flow channel such that a first flow
channel region is defined between a first side of the baffle and
the first end of the spout wall, and a second flow channel region
is located between a second side of the baffle and the second end
of the spout wall, wherein the baffle defines an opening
communicating between the first and second flow channel regions,
said opening having a second width that is smaller than the first
width of the flow channel; and a flexible flow control member
mounted on the cap and including an outlet membrane mounted over
the second end of the spout wall.
2. The beverage container of claim 1, wherein the outlet membrane
comprises at least one of a slit and a plurality of normally-closed
pinholes.
3. The beverage container of claim 1, wherein the outlet membrane
comprises a plurality of normally-closed pinholes formed such that,
when the outlet membrane is subjected to a relatively low pressure
differential and the outlet membrane remains non-deformed, the
plurality of pinholes remain closed to prevent fluid flow between
the fluid flow channel and the external region through the outlet
membrane, and when the outlet membrane is deformed in response to
an applied relatively high pressure differential, the plurality of
pinholes open to facilitate fluid flow through the outlet
membrane.
4. The beverage container according to claim 3, wherein the spout
wall defines a central axis, wherein the outlet membrane is
substantially flat and arranged perpendicular to the central axis,
and wherein the baffle is parallel to the outlet membrane, and the
opening is aligned with the central axis.
5. The beverage container according to claim 1, wherein the spout
wall and the baffle respectively have a greater rigidity than the
outlet membrane such that, when an applied pressure differential is
generated between the fluid flow channel and the external region,
the outlet membrane undergoes a greater deformation than the spout
wall and the baffle.
6. The beverage container according to claim 5, wherein the flow
control member further comprises a tube-like outer spout section
disposed over the spout wall, wherein the outlet membrane is
integrally molded with the outer spout section, and wherein both of
the outer spout section and the outlet membrane comprise at least
one of silicone, a thermoplastic elastomer, and soft rubber.
7. The beverage container according to claim 1, wherein the spout
wall includes a lower spout wall section formed from a relatively
rigid material, and an upper spout wall section formed from a
relatively flexible material, the upper spout wall section having a
lower end that is secured to lower spout wall section and an upper
end that defines an outlet opening, wherein the baffle is
integrally connected to the lower spout wall section, and wherein
the outlet membrane is disposed over the outlet opening of the
upper spout wall section.
8. The beverage container according to claim 1, wherein the flow
control member comprises a substantially flat base portion disposed
on the upper wall of the cap, and a tube-like outer spout section
integrally connected to the base portion and disposed over the
spout wall, and wherein the outlet membrane is integrally connected
to an upper end of the outer spout section.
9. The beverage container according to claim 8, wherein the upper
wall of the cap defines a vent opening, and wherein the base
portion of the flow control member further comprises a vent
membrane disposed over the vent opening, wherein the vent membrane
defines a plurality of normally-closed pinholes.
10. The beverage container according to claim 9, wherein the cap
further comprises a bowl-shaped depression disposed on the upper
wall, wherein the vent opening is defined in the bowl-shaped
depression, and wherein the vent membrane is disposed over and
spaced from the bowl-shaped depression.
11. The beverage container according to claim 10, wherein the cap
further comprises an annular groove surrounding the bowl-shaped
depression, wherein the flow control member includes an annular rib
extending from a lower surface of the base portion and surrounding
the vent membrane, wherein the flow control member is mounted on
the cap such that the annular rib is received in the annular
groove.
12. The beverage container according to claim 8, wherein the upper
wall of the cap further defines a socket, and wherein the flow
control member further comprises a safety button extending from a
lower surface of the base portion and engaged in the socket such
that an end section of the safety button is disposed on a lower
surface of the upper wall of the cap.
13. The beverage container according to claim 12, wherein the upper
wall of the cap defines a recess surrounding the spout wall and the
socket, and wherein the base portion of the flow control member is
mounted in the recess such that an upper surface of the base
portion is flush with an upper surface of the upper wall of the
cap.
14. A beverage container comprising: a container body defining a
beverage storage chamber and an opening; a cap mounted on the
container body such that an upper wall of the cap covers the
opening, wherein the cap includes a spout opening and a vent
opening; and a flexible flow control member mounted on the cap and
including a vent membrane disposed over the vent opening, wherein
the vent membrane defines a plurality of normally-closed pinholes
formed such that when the vent membrane is subjected to a
relatively low pressure differential and the membrane remains
undeformed, the plurality of pinholes remain closed to prevent air
flow through the vent membrane and the vent opening into the
beverage storage chamber, and when the vent membrane is deformed in
response to an applied relatively high pressure differential, the
plurality of pinholes open to facilitate air flow through the vent
membrane and the vent opening into the beverage storage
chamber.
15. The non-spill beverage container according to claim 14, wherein
the cap further comprises a bowl-shaped depression disposed on the
upper wall, wherein the vent opening is defined in the bowl-shaped
depression, and wherein the vent membrane is disposed over and
spaced from the bowl-shaped depression.
16. The non-spill beverage container according to claim 14, wherein
the flexible flow control member includes a base portion disposed
on the upper wall of the cap, and wherein the vent membrane is
disposed on the base portion.
17. The non-spill beverage container according to claim 16, wherein
the cap further comprises a tube-like spout wall disposed on the
upper wall, the spout wall defining a fluid flow channel
communicating between the beverage storage chamber and the spout
opening, and wherein the flow control member further comprises a
spout portion having a relatively thick wall section integrally
connected to the base portion and mounted on the spout wall, and an
outlet membrane disposed at an upper end of the wall section and
positioned over the spout opening.
18. The beverage container according to claim 17, wherein the upper
wall of the cap further defines a socket, and wherein the flow
control member further comprises a safety button extending from a
lower surface of the base portion and engaged in the socket such
that an end of the safety button is disposed on a lower surface of
the upper wall of the cap.
19. A beverage container comprising: a container body defining a
beverage storage chamber and an opening; a cap mounted on the
container body such that an upper wall of the cap covers the
opening, wherein the cap includes a socket opening defined in the
upper wall, and a spout structure including a tube-like spout wall
extending from the upper wall and defining a fluid flow channel
therethrough; and a flexible flow control member mounted on the
cap, the flexible control member including: a substantially flat
base portion disposed on the upper wall of the cap, a tube-like
outer spout section integrally connected to an upper surface of the
base portion and disposed over the spout wall, and a safety button
extending from a lower surface of the base portion and engaged in
the socket opening such that an end of the safety button is
disposed on a lower surface of the upper wall of the cap.
20. The beverage container according to claim 17, wherein the cap
defines a vent opening, disposed between the spout wall and the
socket opening, and wherein the flow control member comprises an
outlet membrane that is integrally connected to an upper end of the
outer spout section and disposed over an open end of the spout
wall, and a vent membrane disposed on the base portion and located
over the vent opening.
21. A vent mechanism for a container, the container including an
outer wall defining a storage chamber, the vent mechanism
comprising: a vent opening defined in the outer wall of the
container; and a vent membrane disposed over the vent opening,
wherein the vent membrane defines a plurality of normally-closed
pinholes formed such that when the vent membrane is subjected to a
relatively low pressure differential and the membrane remains
undeformed, the plurality of pinholes remain closed to prevent air
flow through the vent membrane and the vent opening into the
beverage storage chamber, and when the vent membrane is deformed in
response to an applied relatively high pressure differential, the
plurality of pinholes open to facilitate air flow through the vent
membrane and the vent opening into the beverage storage
chamber.
22. A flow control mechanism for a beverage container, the flow
control mechanism comprising: a tube-like spout wall including a
lower wall section and an upper wall section that collectively
define a flow passage and an outlet opening; a baffle disposed in
the flow passage; and an outlet membrane disposed over the outlet
opening, wherein the lower wall section comprises a relatively
rigid material and the upper wall section comprises a relatively
flexible material, and wherein the outlet membrane defines a
plurality of normally-closed pinholes.
Description
RELATED APPLICATIONS
[0001] This application is a continuation-in-part of U.S. Patent
application for "NON-SPILL CONTAINER WITH FLOW CONTROL STRUCTURE
INCLUDING BAFFLE AND ELASTIC MEMBRANE HAVING NORMALLY-CLOSED
PINHOLES", U.S. application Ser. No. 11/131,721, filed May 17,
2005.
FIELD OF THE INVENTION
[0002] The present invention relates to fluid flow control devices
for beverage containers, and more specifically it relates to
elastic flow control members for, e.g., child sippy cups, and adult
"travel" mugs and sports bottles.
RELATED ART
[0003] Sippy cups, travel mugs and sports bottles represent three
types of beverage containers that utilize flow control devices to
control the ingestion of beverage in response to an applied sucking
force. Sippy cups are a type of spill-resistant container typically
made for children that include a cup body and a screw-on or snap-on
lid having a drinking spout molded thereon. An inexpensive flow
control element, such as a soft rubber or silicone outlet valve, is
often provided on the sippy cup lid to control the flow of liquid
through the drinking spout and to prevent leakage when the sippy
cup is tipped over when not in use. Adult non-spill "travel" mugs
are usually fabricated from a thermally insulating material, and
have a narrow spout that restricts flow of a hot beverage (e.g.,
coffee). A valve similar to that used on child sippy cups is
sometimes incorporated into such travel mugs to prevent spills.
Sports bottles are often similar to sippy cups and travel mugs in
that they include container body and cap having a spout with a
pull-open valve or other flow control member.
[0004] "No drip" sippy cup flow control valves typically include a
sheet of the elastomeric material located between the inner cup
chamber and the open end of the drinking spout that defines one or
more slits formed in an X or Y pattern. As a child tilts the
container and sucks liquid through the drinking spout, the slits
yield and the flaps thereof bend outward, thereby permitting the
passage of liquid to the child. When the child stops sucking, the
resilience of the causes the slits to close once more so that were
the cup to be tipped over or to fall on the floor, liquid cannot
pass out of the container through the drinking spout.
[0005] One problem associated with conventional non-spill cups is
that the elastomeric material used to form the slit-type "no drip"
flow control valves can fatigue in the region of the slits and/or
become obstructed over time, and the resulting loss of resilience
can cause leakage when the slit flaps fail to fully close after
use. This failure of the slit flaps to close can be caused by any
of several mechanisms, or a combination thereof. First, repeated
shearing forces exerted at the end of each slit due to repeated use
can cause tearing of the elastomeric material in this region,
thereby reducing the resilient forces needed to close the slit
flaps after use. Second, thermal cycling or mechanical cleaning
(brushing) of the elastomeric material due, for example, to
repeated washing, can cause the elastomeric material to become less
elastic (i.e., more brittle), which can also reduce the resilience
of the slit flaps. Third, solid deposits left by liquids passing
through the slits can accumulate over time to impede the slit flaps
from closing fully.
[0006] A second problem associated with conventional non-spill cups
is that the "no drip" flow control valves are typically located
inside the short, straw-like drinking spout such that a small, open
upper section of the spout is located above the valve. During each
sip, liquid is drawn through the valve (which is pulled open by the
applied suction), and the passes through the open upper section of
the drinking spout into the drinker's mouth. Because the valve
closes at the end of each sip (i.e., when the applied suction is
terminated), a small amount of liquid is typically "trapped"
(retained) in the upper section (i.e., between the now-closed valve
and the open end of the drinking spout). Because the upper end of
the drinking spout is open to the air, this small amount of liquid
can drip or be shaken from the end of the drinking spout and
create, for example spots on a light colored carpet.
[0007] Another problem associated with conventional beverage
containers is that vents are required to allow air into the cup as
liquid is drawn out to prevent a vacuum condition inside the
beverage chamber. Conventional non-spill cups typically utilize
elastomeric vent devices having slits that function in a manner
similar to the conventional flow control valve used in the drinking
spouts, and thus are subject to clogging and tearing problems
similar to those described above with respect to the drinking spout
valve.
[0008] An additional problem associated with child sippy cups is a
safety requirement that no small part of the sippy cup can be
easily removed and ingested by a child, and thus pose a potential
choke-type hazard. To meet this safety requirement, flow control
members are typically secured to the sippy cup cap in a way that
requires removal of the cap from the container body in order to
separate the flow control member from the cap.
[0009] What is needed is a flow control member for beverage
containers (such as child sippy cups and adult travel mugs and
sports bottles) that exhibits superior non-spill, no-drip
characteristics. What is also needed is a flow control member that
automatically adjusts its fluid flow rate to the applied suction,
and avoids the clogging and tearing problems associated with
conventional slit-type elastic flow control structures. What is
also needed is a vent assembly that reliably regulates air pressure
inside a beverage container without leakage. What is also needed is
a flow control member that is securely attached to the sippy cup
such that the flow control member cannot be easily removed by a
child.
SUMMARY
[0010] The present invention is directed to a flexible flow control
member for a beverage container (e.g., a child sippy cup, an adult
travel mug, or a sports bottle) that addresses the various problems
associated with conventional structures by providing at least one
of a spout assembly that utilizes a baffle and membrane mechanism
to eliminate leakage, an air vent mechanism utilizing a vent
membrane including normally-closed pinholes, and a safety button
mechanism for securely attaching the flow control member to the
beverage container cap. In a disclosed embodiment, the beverage
container includes a container body defining a beverage storage
chamber and an upper opening, a cap mounted on the container body
such that an upper wall of the cap covers the upper opening of the
container body, and a flexible flow control element mounted on the
cap in a manner that provides at least one of the outlet membrane
disposed over a spout opening formed in the cap, the vent membrane
disposed over a vent opening formed in the cap, and a safety button
that is securely connected to a socket formed in the cap. Although
the invention is described herein using a specific embodiment that
incorporates all three of these novel features in an integrally
molded flow control member, these novel features may be utilized
independently.
[0011] In accordance with a first aspect of the present invention,
the spout assembly includes a spout structure that utilizes a
baffle disposed in a tube-like spout wall to minimize liquid
pressure on an outlet membrane mounted over an end of the spout
wall. The tube-like spout wall defines a flow channel extending
from the upper wall of the cap to a spout opening, and the baffle,
which is integrally formed on an inside surface of the spout wall.
The baffle includes a wall that is substantially perpendicular to
the flow channel, and defines a relatively small opening (in
comparison to a width of the flow channel) between a beverage
storage chamber and the outlet membrane. The baffle functions to
limit fluid pressure in the region between the baffle and the
outlet membrane (i.e., in the presence of a higher fluid pressure
downstream of the baffle), thereby reducing fluid pressure on the
outlet membrane, and thus reducing the chance of leakage through
the outlet membrane. In one embodiment, the upper portion of the
spout wall is flexible to facilitate flow through the outlet
membrane.
[0012] In one embodiment, the outlet membrane is formed from a
suitable elastomeric material (e.g., soft rubber, thermoplastic
elastomer, or silicone) that is punctured to form multiple,
substantially round pinholes that remain closed to prevent fluid
flow through the membrane and flow channel under normal atmospheric
conditions (i.e., while the membrane remains non-deformed), thereby
providing a desired "no drip" characteristic. Conversely, when
subjected to such an applied pressure differential (e.g., when
sucked on by a child), the membrane stretches (deforms), thereby
causing some or all of the pinholes to open and to facilitate fluid
flow rate through the membrane, which is substantially unimpeded by
the baffle under these conditions. Because the amount that the
pinholes open, and the associated fluid flow through the pinholes,
is related to the applied pressure differential, the present
invention provides a flow control structure that automatically
adjusts its fluid flow rate to the applied suction. In addition,
because the pinholes are substantially round, the pinholes resist
the clogging and tearing problems associated with slit-type flow
control structures.
[0013] In an alternative embodiment, the beverage container
utilizes the spout structure described above (i.e., including the
baffle), but the outlet membrane includes a conventional (e.g.,
slit-like) opening. This alternative embodiment would reduce
dripping through the slit-like opening due to the pressure reducing
function of the baffle, but would be subject to the problems
described above.
[0014] According to another aspect of the invention, the beverage
container includes a vent mechanism including a vent opening that
is defined, for example, in the upper wall of the cap adjacent to
the spout assembly, and a vent (second) membrane that is disposed
over the vent opening. Similar to the outlet membrane mounted over
the spout, the vent membrane includes normally-closed pinholes that
open in response to an applied pressure differential (i.e., a
vacuum condition inside the cup caused by liquid being drawn
through the spout), thereby allowing air to pass through the vent
membrane and vent opening into the cup. The vent membrane closes
when a user finishes drinking and the pinholes close, so beverage
that may be located between the vent opening and the vent membrane
is prevented from passing through the vent membrane, thus avoiding
the dripping problem associated with conventional non-spill
beverage containers. To facilitate deformation of the vent membrane
(e.g., toward the cap to facilitate the venting process), the vent
membrane is spaced from (e.g., supported over) the upper wall of
the cap such that an air gap is present between the vent opening
and the vent membrane. In one embodiment, the vent opening is
disposed in a bowl-shaped depression that is integrally molded with
the upper wall of the cap, and disposed below a round vent
membrane, thus providing a bowl-shaped clearance for deformation of
the round vent membrane to facilitate air flow into the
container.
[0015] According to another embodiment of the present invention,
the flow control member includes a spout portion including a
relatively thick tube-like elastomeric wall that is mounted on the
rigid spout wall and supports the outlet membrane over the spout
opening, and a base portion that is disposed in a recess formed on
the upper wall of the cap, and a safety button that extends from
the base portion and is secured to the cap. The flow control member
is thus secured to the cap at one end by the spout portion, which
is securely mounted on the spout structure of the cap, and at its
opposite end by the safety button, which extends from a lower side
of the base portion and is press-fit into a socket (opening) formed
in the cap. The recess formed in the cap receives the outer edge of
the base portion such that an upper surface of the base portion is
flush with an upper surface of the cap, thereby preventing a child
from lifting the peripheral edge of the base portion and possibly
removing the flow control member. In addition, the safety button is
secured to the socket such that the safety button can only be
easily disconnected from the cap by pushing the safety button
through the socket from the underside surface of the cap, thereby
meeting the safety requirement requiring that the cap be removed
from the container body before the flow control member can be
removed from the cap.
[0016] The present invention will be more fully understood in view
of the following description and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] FIG. 1 is a perspective side view showing a flow control
structure according to a generalized embodiment of the present
invention;
[0018] FIGS. 2(A) and 2(B) are top and cross-sectional side views,
respectively, showing the flow control structure of FIG. 1;
[0019] FIGS. 3(A) and 3(B) are simplified diagrams illustrating
tensile forces generated in flat and curved membranes;
[0020] FIGS. 4(A) and 4(B) are simplified enlarged cross-sectional
views showing a pinhole formed in the flow control element of FIG.
1 in additional detail;
[0021] FIGS. 5(A) and 5(B) are cross-sectional side views showing
the flow control structure of FIG. 1 during operation as a liquid
flow control structure;
[0022] FIGS. 6(A) and 6(B) are cross-sectional side views showing
the flow control structure of FIG. 1 during operation as an air
vent flow control structure;
[0023] FIG. 7 is a perspective side view showing a non-spill
beverage container including a flow control structure according to
an exemplary embodiment of the present invention;
[0024] FIG. 8 is a perspective bottom-side view showing a flow
control element of the beverage container of FIG. 7;
[0025] FIG. 9 is a perspective top-side view showing a cap of the
beverage container of FIG. 7;
[0026] FIG. 10 a cross-sectional side view showing the beverage
container of FIG. 7 in additional detail;
[0027] FIG. 11 is a cross-sectional side view showing the beverage
container of FIG. 11 during use; and
[0028] FIG. 12 is a cross-sectional side view showing a spout
structure according to an alternative embodiment of the present
invention.
DETAILED DESCRIPTION
[0029] The present invention relates to an improved flow control
member for a beverage container. The following description is
presented to enable one of ordinary skill in the art to make and
use the invention as provided in the context of a particular
application and its requirements. As used herein, directional terms
such as "upper", "upwards", "lower", "downward", "front", "rear",
are intended to provide relative positions for purposes of
description, and are not intended to designate an absolute frame of
reference. In addition, the phrases "integrally connected" and
"integrally molded" is used herein to describe the connective
relationship between two portions of a single molded or machined
structure, and are distinguished from the terms "connected", or
"coupled" (without the modifier "integrally"), which indicates two
separate structures that are joined by way of, for example,
adhesive, fastener, clip, threaded screw or movable joint. Various
modifications to the preferred embodiment will be apparent to those
with skill in the art, and the general principles defined herein
may be applied to other embodiments. Therefore, the present
invention is not intended to be limited to the particular
embodiments shown and described, but is to be accorded the widest
scope consistent with the principles and novel features herein
disclosed.
[0030] FIG. 1 is a perspective view showing a flow control
structure 40 according to a generalized embodiment of the present
invention, and FIGS. 2(A) and 2(B) show flow control structure 40
in top plan and cross-sectional side views, respectively, where
FIG. 2(B) is taken along section line 2-2 of FIG. 2(A).
[0031] Flow control structure 40 includes a molded (first) member
50 including a tube-like wall 54 defining a channel 56, a membrane
55 mounted on an upper (first) end 54A of wall 54, and a baffle (or
vent hole structure) 65 mounted inside channel 56 between upper end
54A and a lower end 54B of wall 54. Wall 54 is a relatively rigid
(i.e., compared to membrane 55) tube-like structure extending
generally along a central axis X between upper end 54A and lower
end 54B. As indicated in FIG. 2(A), in one embodiment wall 54 has a
circular cross section having an inner diameter (width) D1. In
other embodiments, wall 54 may have, for example, an oval, square
or rectangular cross section.
[0032] Membrane 55 is relatively elastic (i.e., compared to wall
54) and is connected to wall 54 adjacent to (i.e., at or slightly
inset from) upper end 54A such that membrane 55 is disposed across
channel 56 to impede flow between channel 56 and an external region
ER. In the disclosed embodiment, membrane 55 has a circular outer
perimeter 57 that is secured to upper end 54A of wall 54. In one
embodiment, elastic membrane 55 is formed from a suitable material
(e.g., soft rubber, thermoplastic elastomer, or silicone) having a
thickness T1 in the range of 0.01 to 0.1 inches (more particularly
0.01 to 0.03 inches), and wall 54 is formed from the same material
and has a thickness T2 in the range of 0.05 to 0.12 inches.
According to the present invention, membrane 55 defines a plurality
of spaced-apart pinholes 59 formed using the procedure describe
below such that when membrane 55 is subjected to normal atmospheric
conditions (i.e., remains non-deformed), pinholes 59 remain closed
to prevent fluid flow between channel 56 and external region ER
through membrane 55. As described in additional detail below,
pinholes 59 are also formed such that when membrane 55 is deformed
(stretched) in response to an applied pressure differential between
channel 56 and external region ER, pinholes 59 open to facilitate
fluid flow through membrane 55. Accordingly, pinholes 59 facilitate
adjustable fluid flow through membrane 55 that increases in direct
relation to the applied pressure differential, thereby facilitating
both a non-spill outlet membrane and a leak-proof vent
membrane.
[0033] As indicated in FIG. 2(B), according to an embodiment of the
present invention, membrane 55 is substantially flat (planar) in
its relaxed (i.e., non-deformed or unstretched) state, and lies in
a plane X-Y that is perpendicular to central axis X of channel 56.
Two advantages are provided by making membrane 55 in this manner. A
first advantage, which is illustrated by the simplified diagrams
shown in FIGS. 3(A) and 3(B), is that a flat membrane is easier to
stretch under an applied pressure than a curved membrane. In
particular, as depicted in FIG. 3(A), a pressure P.sub.z applied
perpendicular to substantially flat membrane 55 causes membrane 55
to stretch (e.g., bow downward, as indicated by the dashed membrane
55'). Note that because membrane 55 is substantially flat,
virtually all of the resultant tensile force T generated in
membrane 55 is directed in the X-Y plane (indicated by component
T.sub.x-y), thereby generating little or no component T.sub.z in
the Z-axis direction until the membrane is at least partially
stretched. Because the tension component T.sub.z remains relatively
small, planar membrane 55 is stretched (and the pinholes opened) in
response to a relatively small applied pressure P.sub.z, thereby
facilitating fluid flow through membrane 55 in response to a
relatively small pressure differential. In contrast, as indicated
in FIG. 3(B), a pre-curved membrane 310 generates a significantly
larger tensile force component T.sub.z, thereby requiring a
substantially larger pressure P.sub.z to produce even a minimal
stretching of membrane 310 from its resting position (e.g., as
indicated by deformed membrane 310', shown in FIG. 3(B)). A second
advantage to provided by making membrane 55 substantially flat is
that, as described below, formation of the pinholes is greatly
simplified and facilitated.
[0034] Although the preferred embodiment includes a substantially
flat (planar) membrane, a curved membrane may also be used,
although such membrane would necessarily be relatively thin (i.e.,
relative to a flat membrane formed from the same material) in order
to facilitate a similar amount of deformation in response to an
applied pressure. A problem posed by using a relatively thin
membrane is the increased chance of rupture and/or tearing of the
membrane material, which may result in the unintended ingestion of
membrane material.
[0035] Referring to FIG. 2(A), according to an aspect of the
present invention, membrane 55 defines a plurality of spaced-apart
pinholes 59 that are arranged in a two-dimensional pattern. The
term "spaced-apart" is used to indicate that the pinholes are
separated by regions of non-perforated membrane material (i.e.,
there are no holes, cracks, slits, or other significant structural
weaknesses in the membrane material in the regions separating
adjacent pinholes). The spacing between pinholes 59 is selected
based on the membrane material such that tearing of the membrane
material between adjacent pinholes is avoided under normal
operating conditions (i.e., the pinholes are spaced as far apart as
is practical). Note that arranging pinholes 59 in a two-dimensional
pattern provides the advantage of balancing the distribution of
forces across membrane 55, thereby reducing the chance of tearing
of the membrane material.
[0036] According to an aspect of the present invention, wall 54 and
baffle 65 have a greater rigidity than the membrane 55 such that,
when an applied pressure differential is generated between channel
56 and external region ER, membrane 55 undergoes a greater amount
of deformation than wall 54 and baffle 65. In one embodiment,
membrane 55 and wall 54 are integrally connected to form an
single-piece member 50, which is molded from a suitable material
(i.e., both wall 54 and elastic membrane 55 are molded in the same
molding structure using a single molding material, e.g., silicone,
a thermoplastic elastomer, or soft rubber), and the increased
rigidity is provided by forming wall 54 to include a thickness T1
that is greater than the thickness T2 of membrane 55. In an
alternative embodiment, wall 54 may be formed at least partially
from a relatively rigid material (e.g., a hard plastic), and
membrane 55 may be separately formed from a relatively elastic
material and then secured to wall 54.
[0037] Referring again to FIGS. 1 and 2(A), membrane 55 is depicted
as being secured around its peripheral edge 57 to upper end 54A of
wall 54. Alternatively, membrane 55 may be recessed into flow
channel 56 to avoid damage caused, for example, by gumming or
chewing on the end of flow control structure 40, provided membrane
55 is positioned between baffle 65 and external region ER (i.e., a
small space is provided between baffle 65 and membrane 55 for
reasons set forth below). However, significantly recessing membrane
55 creates an open upper region between the end of flow channel 56
(i.e., upper end 54A of tube-like wall 54) that may undesirably
create a reservoir for small amounts of liquid that can drip after
each sip when membrane 55 is utilized as an outlet valve, as
described above with respect to conventional non-spill beverage
containers.
[0038] In accordance with another aspect of the present invention,
several pinholes 59 are formed in membrane 55 to facilitate liquid
flow from channel 56 to external region ER in response to an
applied pressure differential (e.g., an applied suction). As
indicated in FIG. 4(A), each pinhole 59 is formed by piercing
membrane 55 with a pin 410, or other sharp pointed object, such
that the pinhole is closed by the surrounding elastomeric material
when pin 400 is subsequently removed. In a preferred embodiment,
membrane 55 is stretched in a radial direction by a force F that is
sufficient to increase the diameter of membrane 55 in the range of
1 to 10 percent during the formation of pinholes 59. When the
stretching force F is subsequently removed (i.e., membrane 55
returns to an unstretched state), pinholes 59 are collapsed by the
surrounding membrane material to provide a reliable seal. In
accordance with another aspect, each pin 410 is formed with a
continuously curved (e.g., circular) cross section such that each
pinhole 59 is substantially circular (i.e., does not have a slit or
fold that would be formed by a cutting element having an edge). In
one embodiment, pin 410 has a diameter in the range of 0.020 and
0.065 inches. Note that a pin having a diameter DIA of
approximately 0.063 inches was used in a punch (8 mm depth on
press) to produce successful pinholes in a membrane having a
thickness of approximately 0.02 inches. The number of pinholes 59
and membrane thickness T3 determine the amount of liquid flow
through membrane 55 during use for a given pressure differential,
as discussed below. During operation, as described in additional
detail below, membrane 55 is positioned between a liquid beverage
(not shown) and an external region. While atmospheric equilibrium
is maintained (i.e., the pressure on both sides of membrane 55 is
essentially equal), membrane 55 remains in the unstretched state
illustrated in FIG. 4(A), wherein pinholes 157 remain closed to
prevent leakage. During subsequent use (e.g., when a child sucks on
wall 54 like a straw), a pressure differential is generated in
which a relatively high pressure on the liquid side of membrane 55
becomes greater than the relatively low pressure on the suction
side, thereby causing membrane 55 to stretch outward, as indicated
in FIG. 4(B). The stretching of membrane 55 causes pinholes 59 to
open, thereby allowing the liquid beverage to pass therethrough.
Subsequently, when the pressure differential is relieved (i.e., the
child stops sucking), membrane 55 then returns to its unstretched
state, and pinholes 59 return to the closed state shown in FIG.
4(A). Conversely, when membrane 55 is utilized to function as a
pressure balancing vent, the ambient pressure outside the beverage
container becomes greater than the pressure inside the container as
liquid is drawn out (i.e., through a spout), thereby causing
membrane 55 to stretch inward (i.e., toward the baffle). The
stretching of membrane 55 causes pinholes 59 to open, thereby
allowing air to enter the beverage container through the baffle
opening, thus relieving the pressure differential. Subsequently,
when the child stops sucking, membrane 55 then returns to its
unstretched state, and pinholes 59 return to the closed state shown
in FIG. 4(A). Note that because pinholes 59 do not include slits
that can become weakened and/or trap deposits that can prevent slit
flap closure, the flow control structure of the present invention
facilitates leak-free operation that is substantially more reliable
than that of conventional, slit-based flow control members.
[0039] Baffle 65 is an annular structure located inside channel 56
and spaced from membrane 55 such that an upper (first) flow channel
region 56A is defined between baffle 65 and membrane 55, and a
lower (second) flow channel region 56B is located on a side of
baffle 65 that is opposite to membrane 55 (e.g., between baffle 65
and a beverage reservoir). Flow channel regions 56A and 56B
communicate through opening 67, which has a relatively small
diameter D2 (FIG. 2(A)). In one embodiment, baffle 65 is a
substantially disk-shaped structure that is parallel to membrane 55
(when in its substantially planar, unstretched state), and opening
67 is aligned with the central axis X defined by wall 54. In
alternative embodiments baffle 65 is either integrally connected to
wall 54 and membrane 55 (i.e., formed as part of first member 50,
as depicted in FIG. 2(B)), or fabricated separately from a second
material (e.g., a rigid plastic), and inserted flow channel 56,
such as described below with reference to the disclosed specific
embodiment.
[0040] FIGS. 5(A) and 5(B) are cross-sectional side views showing a
simplified beverage container 500A including flow control structure
40 during operation in accordance with a first aspect of the
present invention in which flow control structure 40 is utilized to
control the flow of a liquid beverage (BVG). Beverage container
500A includes a container body 510A having an outer wall 511
defining a beverage storage chamber 517 containing liquid beverage
BVG, and an opening 519. Flow control structure 40 is mounted over
open end 519 such that flow channel section 56B communicates
directly with chamber 517 via open end 519, and baffle 65 is
positioned between chamber 517 and flow channel section 56A. FIG.
5(A) shows beverage container 500B in an inverted position prior to
use (i.e., such that atmospheric pressure is applied to the outside
surface of membrane 55, and beverage BVG is prevented from leaking
out of container 500B solely by flow control structure 40), and
FIG. 5(B) shows beverage container 500B while a suction is applied
to flow control structure 40 by an external body 530 (e.g., a
child's mouth). In one embodiment, as indicated in FIG. 5(B), wall
54 and baffle 65 respectively have a greater rigidity than membrane
55 such that, when the applied pressure differential is generated
between fluid flow channel 56 and external region ER (e.g., inside
external body 530), membrane 55 undergoes a greater deformation
than wall 54 and baffle 65 in order to, for example, prevent
collapse of flow control structure 40 during use.
[0041] According to another aspect of the present invention, baffle
65 and membrane 55 combine to further enhance the no-drip/non-spill
characteristic of flow control structure 40. First, the inventor
discovered that providing baffle 65 in flow channel 56 limits the
static pressure transmitted to membrane 55 while container 500B is
held in the inverted position indicated in FIG. 5(A). More
specifically, the inventor discovered that placing baffle 65 into
flow channel 56 allowed the inventor to increase the flow rate
characteristics of membrane 55 (e.g., reduce the thickness of
membrane 55 and/or increase the size of pinholes 59), making
membrane 55 more suitable for high volume flow, without increasing
the tendency for membrane 55 to leak in the inverted position. The
inventor currently believes that this beneficial characteristic may
be produced, at least in part, by a combination of baffle 65 acting
to limit the static pressure transferred to flow channel region 56A
from chamber 517, and by surface tension of beverage BVG in and
around opening 67. A second benefit of baffle 65 is that it impedes
relatively high pressure spikes in flow channel region 56A that are
generated, for example, when beverage container 500B is shaken up
and down or dropped while in the inverted position shown in FIG.
5(A). The inventors discovered that, when combined with a membrane
that exhibits leakage in response to such pressure spikes in the
absence of baffle 65, the presence of baffle 65 significantly
reduced and/or eliminated leakage through membrane 55, even when an
associated beverage container is shaken vigorously. As a third
benefit, referring to FIG. 5(B), when subsequently subjected to
suction by external body 530, the relatively high static pressure
differential creates liquid flow through membrane 55 that appears
to be minimally impeded by baffle 65. Accordingly, the inventor
found that by combining the increased flow rate characteristics of
membrane 55 with baffle 65, flow control structure 40 provides
superior non-spill, no-drip characteristics, compared to
conventional non-spill designs. Further, membrane 55 operates as
described above to automatically adjust the fluid flow rate through
flow control structure 40 to the applied suction, and to avoid the
clogging and tearing problems associated with conventional
slit-type elastic flow control structures.
[0042] FIGS. 6(A) and 6(B) are cross-sectional side views showing a
simplified beverage container 500B during operation in accordance
with a second aspect of the present invention in which flow control
structure 40 is utilized as a vent mechanism to regulate air
pressure inside beverage container 500B. Beverage container 500B
includes a container body 510B having an outer wall 511 defining a
beverage storage chamber 517 containing a liquid beverage BVG, an
opening 519, and a spout 520 having a flow channel 525. Flow
control structure 40 is mounted over opening 519 such that baffle
65 is positioned between chamber 517 and membrane 55. FIG. 6(A)
shows beverage container 500B in an equilibrium state prior to use
(i.e., such that atmospheric pressure is equal to the air pressure
in region 66B above chamber 517), and FIG. 6(B) shows beverage
container 500B while a suction is applied to spout 520 by an
external body (not shown). As indicated in FIG. 6(B), as beverage
BVG is drawn out of chamber 517 through flow channel 525 (indicated
by dark-line arrow), the resulting drop in air pressure in region
66B causes an applied pressure differential that draws (vent)
membrane 55 toward baffle 65, thus opening pinholes 59 in the
manner described above and allowing air from external region ER to
enter chamber 517 by way of opening 67 (as indicated by dashed-line
arrow). Once the air pressure in region 66B equalizes with external
region ER, membrane 55 returns to the unstretched state depicted in
FIG. 6(A), and pinholes 59 close to form an airtight, watertight
seal between chamber 517 and external region ER. In this
embodiment, baffle 65 serves as a vent opening to resist the flow
of liquid into region 66A between baffle 65 and membrane 55, and as
such opening 67 may be relatively smaller than the embodiment
depicted in FIGS. 5(A) and 5(B) (i.e., because opening 67 is used
to transmit air, not liquid).
[0043] The present invention will now be described with reference
to a specific embodiment.
[0044] FIG. 7 is perspective top-side view showing a non-spill
beverage container 600 that utilizes a flow control member 640 that
is formed in accordance with a specific embodiment of the present
invention. Container 600 generally includes a hollow cup-shaped
container body 610, a cap 620 mounted on body 610, and flow control
member 640, which is mounted on cap 620.
[0045] In accordance with an aspect of the present embodiment, flow
control structure 640 is an integral (molded) flexible structure
including a spout portion 650 having a tube-like outer spout
section 654 and an outlet membrane 655 formed at an upper end
thereof, a substantially flat base portion 660 having a vent
membrane 665 formed thereon, and an engagement portion 670 disposed
at an end of base portion 660 that is opposite to spout portion
650. Outlet membrane 655 and vent membrane 665 are constructed in
the manner described above with reference to FIGS. 1-4 (i.e.,
outlet membrane 655 includes multiple normally-closed pinholes 659,
and vent membrane 665 includes multiple normally-closed pinholes
669), where outlet membrane 655 functions to control liquid flow in
the manner described above with reference to FIGS. 5(A) and 5(B),
and vent membrane functions to allow air into container 600 in the
manner described above with reference to FIGS. 6(A) and 6(B).
[0046] FIG. 8 is a perspective bottom-side view showing flow
control member 640 in additional detail. Flow control member 640 is
integrally molded or otherwise formed from a relatively flexible
elastomeric material (e.g., soft rubber, thermoplastic elastomer,
or silicone) using both known techniques and those described above
with reference to fabrication of the pinhole membranes. Base
portion 660 of flow control member 640 is a generally flat, oblong
structure having a front end 660F and a rear end 660R. Spout
portion 650 extends from upper surface 662 of base section 660
adjacent to front end 660F, and defines a central passage 656 that
extends between membrane 655 and a lower surface 663 of base
section 660. A relatively thick front flange 664 surround the lower
opening of central passage 656. Also disposed on a lower surface
663 are an annular rib 667 that surrounds vent membrane 665, and a
safety button 675 that is located adjacent to rear end 660R (i.e.,
such that vent membrane 665 is located between spout portion 650
and safety button 675). Safety button 675 includes a relatively
narrow base section 676 extending from lower surface 663, a
relatively wide end section 677, and defines a hollow central
region 679 that facilitates insertion into a corresponding socket
hole formed in cap 620 as described below.
[0047] FIG. 9 is a top-side perspective view showing cap 620 in
additional detail. Cap 620 generally includes a substantially
cylindrical (vertical) base portion 621, and a substantially flat
or slightly domed (horizontal) upper wall 625 having an upper
surface 622 that is supported on an upper edge of base portion 621.
A spout structure 630 including a rigid tube-like spout wall 634
extends upward from upper wall 625, and includes therein a baffle
635 that defines a relatively small opening 637. Disposed adjacent
to spout structure 630 is a bowl-shaped depression 628 that defines
a vent opening 627. A socket opening 629 is defined through upper
wall 625 and disposed such that depression 628 is positioned
between socket opening 629 and spout structure 650. Cap 620
includes an oblong recess 680 that surrounds spout structure 630,
depression 628 and socket opening 629, and has a peripheral edge
681 that is shaped to receive base portion 660 of flow control
element 640 (FIG. 8). Recess 680 includes a relatively deep section
684 located at a front end 680F for receiving flange 664 (FIG. 8),
and an annular groove 687 surrounding depression 628 for receiving
annular rib 667 (FIG. 8). The engagement of annular rib 667 in
annular groove 687 facilitates both positioning and support of vent
membrane 665 over bowl-shaped depression 628.
[0048] FIG. 10 is a simplified cross-sectional side view showing
beverage container 600 with flow control membrane 640 mounted on
cap 620, and cap 620 mounted on container body 610.
[0049] As shown in FIG. 10, container body 610 includes a roughly
cylindrical sidewall 611 having a threaded upper edge 613 defining
an upper opening 612, and a bottom wall 615 located at a lower edge
of sidewall 611. Base portion 621 of cup 620 has threaded inside
surface that mates with threaded upper edge 613 to connect cap 620
to body 610. Sidewall 611 and bottom wall 615 of container body 610
combine with upper wall 625 of cap 620 to define an outer wall of
container 600 surrounding a beverage storage chamber 617 in which a
beverage is received during use. Tube-like spout wall 634 of spout
structure 630 has a lower end 634B that is integrally molded to
upper wall 625 and an upper (free) end that defines an upper
opening 638, and defines a flow channel 636 that extends between
beverage storage chamber 617 and upper opening 638. Baffle 635 is
integrally molded to an inside surface of rigid spout 630 such that
baffle 635 is positioned between a lower end 634B and an upper end
634A of spout wall 634, thereby effectively dividing flow channel
636 into a lower channel region 636B and an upper channel region
636A. In addition, baffle 635 defines relatively small opening 637
that facilitates fluid flow between lower channel region 636A and
upper channel region 636B in the manner described above with
reference to FIGS. 5(A) and 5(B).
[0050] According to another aspect of the present invention that is
depicted in FIG. 10, flow control member 640 is mounted onto cap
620 such that spout portion 650 is securely (i.e., with a tight
fit) mounted over rigid spout wall 634, and both cap 620 and flow
control member 640 are fabricated such that side edges 661 of base
portion 660 are tightly (i.e., without a significant gap) received
inside peripheral edge 681 of recess 680 (see FIG. 7). In addition,
recess 680 is formed to receive base portion 660 such that upper
surface 662 is flush (e.g., coplanar) with upper surface 622 of cap
620 (which is also shown in FIG. 7). As further depicted in FIG.
10, relatively thick flange 664 is mounted inside deep recess
section 684 such that front end 660F of base portion 660 is
securely held onto cap 620 in a manner that prevents a small child
from prying front end 660F upward from cap 620. Finally, rear end
660R of base portion 660 is securely held against upper wall 625 by
safety button 675, which is inserted through socket opening 629 in
the manner shown in FIG. 10 such that end portion 677 of safety
button 675 is disposed on a lower surface 623 of upper wall 625.
With this arrangement, flow control member 640 is secured to cap
620 in a manner that prevents a child from removing flow control
member 640 while cap 620 is mounted on container body 610. That is,
the only practical way to remove flow control member 640 from cap
620 (e.g., for cleaning purposes) is to remove cap 620 from
container body 610, and then applying a force F (indicated by dark
arrow in FIG. 10) against end section 677 that is sufficient to
push safety button 675 through socket opening 629, thus disengaging
rear end 660R from upper wall 625. With rear end 660R thus
disengaged, removal of flow control member 640 is then completed by
removing front end 660F from spout structure 630 (e.g., by pulling
rear end 660R upward from cap 620). Because a small child typically
does not have the hand strength necessary to remove cap 620 and/or
to push safety button 675, the present invention provides a
substantially child-proof structure that also provides the many
benefits described above.
[0051] FIG. 11 is a cross-sectional side view showing the non-spill
beverage container 600 in a tipped position whereby a beverage BVG
is able to flow to membrane 655 by way of lower flow channel region
636B, baffle opening 637, and upper flow channel region 636A. As
described above with reference to the generalized embodiment,
baffle 635 and membrane 655 combine to prevent leakage when a user
is not applying suction to the end of spout 634/654. When suction
is applied by a user (not shown), the applied pressure differential
causes membrane 655 to bend outward to open pinholes 659 in the
manner described above. As beverage BVG is drawn by the user
through spout 634/654, the resulting vacuum generated in storage
chamber 617 is equalized by the inward deformation of vent membrane
665, which allows air to enter way of vent hole 627.
[0052] In accordance with another benefit of the present invention
because membrane 655 is located at the end of spout 634/654, when a
user finishes drinking and membrane 655 closes, beverage that may
be retained in upper flow channel region 656A is prevented from
dripping or otherwise discharging from spout 634/654, thus avoiding
the dripping problem associated with conventional non-spill
beverage containers.
[0053] In addition to the general and specific embodiments
disclosed herein, other features and aspects may be added to the
novel flow control structures that fall within the spirit and scope
of the present invention. Therefore, the invention is limited only
by the following claims.
[0054] For example, one or more of the novel features described
herein (e.g., the vent mechanism) may be utilized separately from
the other features (e.g., in conjunction with a conventional, slit
type spout structure), and the features may also be used in other
types of beverage containers, such as sports bottles or other
hydration systems. In such alternative embodiments, the vent
opening would be formed in an outer wall of the container and the
vent membrane disposed over the vent hole in a manner similar to
that described in the embodiments described above.
[0055] In another alternative embodiment shown in FIG. 12, a flow
control mechanism 700 for a beverage container (e.g., a cup such as
that described above, a sports bottle, or a hands-free hydration
pack such as those produced by Camelbak Products, LLC of Petaluma,
Calif., USA) includes a spout wall 734 and a flexible spout (flow
control) member 750. Spout wall 734 includes a lower spout wall
section 734B and an upper spout wall section 734A defining a flow
channel 736 having a lower section 736B and an upper section 736A.
Lower spout wall section 734B comprises a relatively rigid (e.g.,
hard molded plastic). A baffle 735 is integrally molded to an upper
end of lower spout wall section 734B, and includes a relatively
small opening 737 that communicated between lower flow channel
section 736B and upper flow channel section 736A. Upper spout wall
section 734A comprises a relatively flexible (e.g., rubber) upper
spout wall section 734A that has a lower end attached to lower
stout wall section 734B using known overmolding techniques, and an
upper end that defines an outlet opening 738. Similar to the flow
control member described above, spout member 750 includes a
tube-like outer spout section 754 that mounts over upper spout wall
section 734A, and an outlet membrane 755 that is disposed over
outlet opening 738. Membrane 755 includes normally-closed pinholes
formed in the manner described above. In one embodiment, lower wall
section 734B is integrally molded with the cap (not shown) in the
manner described above, and tube-like outer spout section 754A
extends from the base portion of a flow control member (not shown)
in the manner described above. In another embodiment, spout wall
734 and spout member 750 form a drinking nozzle that, for example,
is provided on a sports bottle or hydration pack. The benefit of
forming upper spout wall section 734A from a relatively flexible
material (i.e., in comparison to lower spout wall section 734B) is
that the flexible material facilitates bending of the upper end of
outer spout section 754A in an inward direction (i.e., in the
direction of the arrows in FIG. 12), thereby a user to enhance
fluid flow through membrane 755 by biting upper spout wall section
734A/outer spout section 754A, thereby causing membrane 755 to flex
in a manner that opens the normally-closed pinholes (not shown)
that are formed therein.
* * * * *